flexiblefullpage
billboard
interstitial1
catfish1
Currently Reading

Katerra, a tech-driven GC, plots ambitious expansion

Multifamily Housing

Katerra, a tech-driven GC, plots ambitious expansion

Investors flock to this vertically integrated startup, which automates its design and construction processes.


By John Caulfield, Senior Editor | March 4, 2018

Katerra's sole factory, in Phoenix, produces wall panels, roof and floor trusses, cabinets, and countertops. The company, which recently raised $865 million in new venture capital financing, expects to have five more plants operating by year's end. Image: Katerra

By this time next year, Katerra—a technology startup whose end-to-end business model combines prefabrication, architectural, and construction services primarily for multifamily housing—expects to have six manufacturing plants up and running, including its first mass timber factory, a 250,000-sf building under construction on 29 acres in Spokane, Wash.

That plant, when fully operational in early 2019, will be capable of producing about 4.6 million cubic feet of cross-laminated timber annually. The plant’s size is comparable to CLT factories operating in Europe. “We’re going all in on CLT,” says Trevor Schick, who oversees Katerra’s supply chain, lighting, renovation, and commercial rollout activities.

Katerra’s initial success—it booked $1.3 billion in business last year—and its aggressive growth posture have attracted several high-profile investors, most prominently Japan’s SoftBank, from whose $100 billion Vision Fund Katerra recently raised $865 million in its latest round of financing.

SoftBank is steadily investing in tech-oriented companies that are impacting the built environment. In December, it paid $9.3 billion to acquire a 15% stake in Uber Technologies. It owns the robotics manufacturer and research firm Boston Dynamics. Last summer, SoftBank invested $200 million in the indoor farming enterprise Plenty. And it holds a $4.4 billion stake in WeWork, the cosharing office developer.

TechCrunch reported that the venture-capital world fully expects SoftBank to raise another $100 billion for future investments soon.

In-house design team and consortium

The Menlo Park, Calif.-based Katerra is already among the country’s largest GCs. The housing markets it serves include multifamily, senior and student living, and master-planned developments. Katerra’s largest customer is The Wolff Company, a real estate private equity firm that focuses on the multifamily sector, and whose executive chairman Fritz Wolff was one of Katerra’s Co-founders.

“Having a lead customer is important, given the investment we’re making in factories, IT, and so forth,” says Schick.

Katerra currently produces wall panels, roof and floor trusses, cabinets, and countertops from its factory in Phoenix, which began production in early 2017. That facility features Katerra’s Design Showroom, where clients can view a full suite of products and interior design solutions, including fully finished apartment units made entirely from Katerra-supplied products.

Union Bay South in Carson, Calif., designed by Architects Orange, will offer 357 residential units, with four- and five-story wood framed buildings wrapping two separate concrete parking structures. The building, currently under construction, will include 30,000 sf of retail. Katerra is providing construction, management, and materials. Image: Katerra

 

Last June, Katerra acquired Nystrom Olson, a boutique architectural studio in Spokane. And six months later, it announced the forming of a design consortium whose members include Michael Green of Michael Green Architecture, a leader in mass timber architectural design; Andrea Leers of Boston-based Leers Weinzapfel Associates, which has also designed buildings using mass timber; Ted Flato of Lake|Flato in Texas; and Joe Greco of Lord Aeck Sargent, a full-service architecture and design firm with six offices.

With Green, Katerra is working on the design and construction of the new Hospitality Center in association with the Community Cancer Fund, Ronald McDonald House and Kootenai Health (Walden House) in Coeur d’Alene, Idaho.

Schick tells BD+C that, aside from the CLT plant in Washington, the other facilities Katerra moves into or builds this year will be conventional wood panel and truss factories. Its next mass timber plant is likely to be located in the Southeastern U.S., although Schick didn’t say when construction for that might start.

Leaning toward mass production

Katerra started as a materials supplier, with sourcing offices in Asia and Mexico. But the company soon realized that it needed a “larger scale” to get its cost model right, says Schick. That meant taking more control over the design, production, construction, and logistics of what it sold.

Technology has been the key to that transformation. Before joining Katerra, Schick spent over 15 years in the electronics industry, most recently as senior vice president at Hewlett-Packard involved in global supply chain and quality. One of Katerra’s Co-founders, Michael Marks, had been CEO of an electronics company now called Flex. A third Co-founder, Jim Davidson, founded Silver Lake, a technology investment firm.

Marks is convinced that building construction would benefit greatly from mass production techniques that are common in electronics and automotive manufacturing. Consequently, Katerra uses a kit-of-parts design system that it combines with prefabricated components production and onsite assembly.

The company’s technology platforms include SAP HANA, a market analytics platform that mines data from real estate and construction; a mobile app that connects its workforce in the field; and industrial IoT tools that optimize jobsite activity and track inventory. 

 

Katerra is building its first mass timber factory, a 250,000-sf building in Spokane, Wash., which will be able to produce 4.6 million cubic feet of product annually. Image: Katerra

 

Schick says the company currently has 12 multifamily projects under way, ranging from 200 to 400 housing units per project. Sometime this year, he says the company plans to enter the hotel construction sector. Katerra also wants to build schools eventually.

As for projects using mass timber, Schick believes that demand among developers, contractors, and cities can only go up. He notes that the International Code Council has a vote scheduled for April to amend the 2021 International Building Code to allow for the use of CLT for buildings up to 18 stories. (Currently, CLT is limited in the U.S. to buildings no higher than six stories.)

In Washington State, ESB Bill 5450, which has passed both chambers of the legislature and is on the governor’s desk to sign, creates a section in the state statute defining qualifying mass timber products. It also directs the State Building Code Council to adopt rules for the use of mass timber in residential and commercial building, consistent with application national and international standards.

Katerra is already doing fire, earthquake, and wind sheer testing of CLT panels that it can make on its 60-foot-long by 12-foot-wide press.

Related Stories

Laboratories | Jun 23, 2023

A New Jersey development represents the state’s largest-ever investment in life sciences and medical education

In New Brunswick, N.J., a life sciences development that’s now underway aims to bring together academics and researchers to work, learn, and experiment under one roof. HELIX Health + Life Science Exchange is an innovation district under development on a four-acre downtown site. At $731 million, HELIX, which will be built in three phases, represents New Jersey’s largest-ever investment in life sciences and medical education, according to a press statement.

Sports and Recreational Facilities | Jun 22, 2023

NFL's Jacksonville Jaguars release conceptual designs for ‘stadium of the future’  

Designed by HOK, the Stadium of the Future intends to meet the evolving needs of all stadium stakeholders—which include the Jaguars, the annual Florida-Georgia college football game, the TaxSlayer.com Gator Bowl, international sporting events, music festivals and tours, and the thousands of fans and guests who attend each event.

Contractors | Jun 22, 2023

Chris Averill named President of Pepper Construction Group 

Pepper Construction Group is pleased to announced the promotion of Chris Averill to the position of President. In his new role, Averill will assume leadership responsibility for the Pepper Construction Group’s growth and performance.

Industrial Facilities | Jun 20, 2023

A new study presses for measuring embodied carbon in industrial buildings

The embodied carbon (EC) intensity in core and shell industrial buildings in the U.S. averages 23.0 kilograms per sf, according to a recent analysis of 26 whole building life-cycle assessments. That means a 300,000-sf warehouse would emit 6,890 megatons of carbon over its lifespan, or the equivalent of the carbon emitted by 1,530 gas-powered cars driven for one year. Those sobering estimates come from a new benchmark study, “Embodied Carbon U.S. Industrial Real Estate.”

Virtual Reality | Jun 16, 2023

Can a VR-enabled AEC Firm transform building projects?

With the aid of virtual reality and 3D visualization technologies, designers, consultants, and their clients can envision a place as though the project were in a later stage.

Mechanical Systems | Jun 16, 2023

Cogeneration: An efficient, reliable, sustainable alternative to traditional power generation

Cogeneration is more efficient than traditional power generation, reduces carbon emissions, has high returns on the initial investment, improves reliability, and offers a platform for additional renewable resources and energy storage for a facility. But what is cogeneration? And is it suitable for all facilities?

AEC Innovators | Jun 15, 2023

Rogers-O'Brien Construction pilots wearables to reduce heat-related injuries on jobsites

Rogers-O'Brien Construction (RO) has launched a pilot program utilizing SafeGuard, a safety-as-a-service platform for real-time health and safety risk assessment. Non-invasive wearables connected to SafeGuard continuously monitor personnel to prevent heat exhaustion on jobsites, reducing the risk of related injuries. RO is the first general contractor to pilot this program.

Office Buildings | Jun 15, 2023

An office building near DFW Airport is now home to two Alphabet companies

A five-minute drive from the Dallas-Fort Worth International Airport, the recently built 2999 Olympus is now home to two Alphabet companies: Verily, a life sciences business, and Wing, a drone delivery company. Verily and Wing occupy the top floor (32,000 sf and 4,000 sf, respectively) of the 10-story building, located in the lakeside, work-life-play development of Cypress Waters.

Transit Facilities | Jun 15, 2023

Arlington, Va., transit station will support zero emissions bus fleet

Arlington (Va.) Transit’s new operations and maintenance facility will support a transition of their current bus fleet to Zero Emissions Buses (ZEBs). The facility will reflect a modern industrial design with operational layouts to embrace a functional aesthetic. Intuitive entry points and wayfinding will include biophilic accents.

Urban Planning | Jun 15, 2023

Arizona limits housing projects in Phoenix area over groundwater supply concerns

Arizona will no longer grant certifications for new residential developments in Phoenix, it’s largest city, due to concerns over groundwater supply. The announcement indicates that the Phoenix area, currently the nation’s fastest-growing region in terms of population growth, will not be able to sustain its rapid growth because of limited freshwater resources. 

boombox1
boombox2
native1

More In Category




halfpage1

Most Popular Content

  1. 2021 Giants 400 Report
  2. Top 150 Architecture Firms for 2019
  3. 13 projects that represent the future of affordable housing
  4. Sagrada Familia completion date pushed back due to coronavirus
  5. Top 160 Architecture Firms 2021